Outlet accommodating out-of-specification plugs

ABSTRACT

A telecommunications outlet includes: a housing that is shaped to receive a plug, the housing having a support disposed within the housing; and a first contact having a first end, a second end, and a bend section, the bend section is supported by the support, wherein the first contact includes a first reverse curve section disposed between the first end and the bend section.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of the date of the earlierfiled provisional application, having U.S. Provisional Application No.60/370,042, filed on Apr. 4, 2002, which is incorporated herein in itsentirety.

BACKGROUND OF THE INVENTION

The invention relates generally to modular outlets and in particular toa modular outlet that accommodates an out-of-specification plug. Modularoutlets are used in a variety of applications such as patch panels,couplers, etc. Modular outlets typically include a number of resilientmetal contacts the make electrical contact with contacts on a plug. Theoutlet contacts typically deflect slightly upon mating with a plugmeeting certain specifications. When an out-of-specification plug ismated with an outlet, this may cause the outlet contacts to bend and/ordeform. Such deformation may cause the outlet to fail to make contactwith a subsequent plug resulting in an open circuit failure.

SUMMARY OF THE INVENTION

A telecommunications outlet includes: a housing that is shaped toreceive a plug, the housing having a support disposed within thehousing; and a first contact having a first end, a second end, and abend section, the bend section is supported by the support, wherein thefirst contact includes a first reverse curve section disposed betweenthe first end and the bend section.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alikein the several FIGURES:

FIG. 1 is an exploded perspective view of an outlet with no plug.

FIG. 2 is a front view of the outlet of FIG. 1.

FIG. 3 is a back view of the outlet of FIG. 1.

FIG. 4 is a cross sectional view of the outlet of FIG. 1, shown at afirst contact position.

FIG. 5 is a cross sectional view of the outlet of FIG. 1, shown at asecond contact position.

FIG. 6 is a cross sectional view of the outlet of FIG. 1, shown at athird contact position.

FIG. 7 is a cross sectional view of the outlet of FIG. 1 at the firstcontact position receiving an in-specification 8 position plug.

FIG. 8 is a cross sectional view of the outlet of FIG. 1 at the firstcontact position receiving an in-specification 8 position plug.

FIG. 9 is a cross sectional view of the outlet of FIG. 1 at the firstcontact position receiving an out-of-specification 8 position plug.

FIG. 10 is a cross sectional view of the outlet of FIG. 1 at the firstcontact position receiving a 6 position plug.

FIG. 11 is a cross sectional view of the outlet of FIG. 1 at the thirdcontact position receiving an in-specification plug.

FIG. 12 is a cross sectional view of the outlet of FIG. 1 at the thirdcontact position receiving an in-specification plug.

FIG. 13 is a cross sectional view of the outlet of FIG. 1 at the thirdcontact position receiving an out-of-specification 8 position plug.

DETAILED DESCRIPTION

FIG. 1 is an exploded perspective view of an outlet 100 having a housing102 and a front opening 104. The front opening 104 receives a standardplug as known in the art. Outlet 100 includes a contact section 106,which includes nine contacts, which are numbered 1-9. While outlet 100is shown with nine contacts, there may also be only eight contacts. Thecontacts commonly form tip and ring pairs. In one embodiment, contacts 1and 2 form a tip and ring pair, contacts 3 and 6 form a tip and ringpair, contacts 4 and 5 form a tip and ring pair, contacts 7 and 8 form atip and ring pair. In addition, FIGS. 2 and 3 illustrate the front viewand the back view of outlet 100, respectively. A more detaileddescription of the back view of outlet 100 can also be found in FIGS.37-42 and its related description in the specification of U.S. Pat. No.6,213,809, which is herein incorporated by reference in its entirety.

FIG. 4 is a cross sectional view of outlet 100 taken at contact 1.Contact 1 includes a termination end 120 that exits a rear 122 ofhousing 102 and a distal end 124 that is secured within housing 102 byplacing distal end 124 under a front lip 126 of housing 102. Terminationend 120 may be a solder tail, press-fit tail, etc. From termination end120, contact 1 bends from the horizontal direction to the verticaldirection, which is approximately 90 degrees, to define a first leg 130.Contact 1 then bends again at a bend section 132 and proceeds to areverse curve section 140. A support 134 formed within housing 102supports first leg 130 and bend section 132. In addition, an extension136 extends from housing 102 to also support first leg 130.

Alternatively, termination end 120 may extend from a bottom 150 ofhousing 102. In this embodiment, termination end 120 proceeds in avertical direction along support 134 and then bends at bend section 132to reverse curve section 140.

Reverse curve section 140 includes a concave portion 142 and a convexportion 144. Concave portion 142 is formed closer to termination end 120than convex section 144. Convex section 144 is formed closer to a distalend 124 than concave portion 142.

Convex portion 144 includes a first slope 160 and a second slope 162.Both first slope 160 and second slope 162 may be defined by angles a andb, respectively, which are formed from the horizontal direction. Thehorizontal direction is defined at a bottom floor 170 of opening 104. Ascan be seen in FIG. 4, the orientation of angle a and angle b are fromopposite directions. Angle a, which is oriented from the rear of outlet100, may range up to and including an angle of 45°, with a preferableangle of 45°. Angle b, which is oriented from the front of outlet 100,may range from 12° to 20°, with a preferable angle of 19°. In addition,a height 172 of convex portion 144 from bottom floor 170 may range fromabout 0.8 inches to about 1.05 inches, with a preferable height ofapproximately 0.92 inches.

It should be noted that a height 180 of support 134 may be adjusted toaccommodate the various angles. In addition, height 180 may remainconstant and the change in the angles may be made by changing the bendof reverse curve section 140. In addition, at the preferred angles of45° and 19° for angles a and b, respectively, height 180 extends abovebottom floor 170.

Within outlet 100, contacts 1, 8, and 9 are the same structure and thus,the description described as to contact 1 also applies to contacts 8 and9.

FIG. 5 is a cross sectional view of outlet 100 taken at contact 2.Contact 2 includes a termination end 220 that exits rear 122 of housing102 and a distal end 224 that is secured within housing 102 by placingdistal end 224 under front lip 126 of housing 102. Termination end 220may be a solder tail, press-fit tail, etc. From termination end 220,contact 2 bends from the horizontal direction to the vertical direction,which is approximately 90 degrees, to define a first leg 230. Contact 2then bends again at a bend section 232 and proceeds to a reverse curvesection 240. A support 234 formed within housing 102 supports first leg230 and bend section 232. In addition, an extension 236 extends fromhousing 102 to also support first leg 230.

Alternatively, termination end 220 may extend from bottom 150 of housing102. In this embodiment, termination end 220 proceeds in a verticaldirection along support 234 and then bends at bend section 232 toreverse curve section 240.

Reverse curve section 240 includes a concave portion 242 and a convexportion 244. Concave portion 242 is formed closer to termination end 220than convex section 244. Convex section 244 is formed closer to a distalend 224 than concave portion 242.

Convex portion 244 includes a first slope 260 and a second slope 262.Concave portion 242 includes second slope 262 and a third slope 264.Both first slope 260 and second slope 262 may be defined by angles a′and b′, respectively, which are formed from the horizontal direction.The horizontal direction is defined at bottom floor 170 of opening 104.As can be seen in FIG. 5, angles a′ and b′ are both oriented in the samedirection. Angle a′, which is oriented from the rear of outlet 100, mayrange up to and including an angle of 45°, with a preferable angle of45°. Angle b′, which is also oriented from the rear of outlet 100, mayrange from 7° to 12°, with a preferable angle of 9.5°. Convex portion242 may also be defined by an angle c, which defines the angle betweensecond slope 262 and third slope 264. Angle c preferably has a maximumangle of 163°.

In addition, a height 272 of convex portion 244 from bottom floor 170may range from about 0.85 inches to about 1.15 inches, with a preferableheight of approximately 0.92 inches.

It should be noted that a height 280 of support 234 may be adjusted toaccommodate the various angles. In addition, height 280 may remainconstant and the change in the angles may be made by changing the bendof reverse curve section 240. At the preferred angles of 45° and 9.5°for angles a′ and b′, respectively, height 280 extends above bottomfloor 170. In addition, height 280 is greater than height 180.

Within outlet 100, contacts 2, 4, and 6 are the same structure and thus,the description described as to contact 2 also applies to contacts 4 and6.

FIG. 6 is a cross sectional view of outlet 100 taken at contact 3.Contact 3 includes a termination end 320 that exits rear 122 of housing102 and a distal end 324 that is secured within housing 102 by placingdistal end 324 under front lip 126 of housing 102. Termination end 320may be a solder tail, press-fit tail, etc. From termination end 320,contact 3 bends from the horizontal direction to the vertical direction,which is approximately 90 degrees, to define a first leg 330. Contact 3then bends again at a bend section 332 and proceeds to a curve section340. A support 334 fanned within housing 102 supports first leg 330 andbend section 332. In addition, an extension 336 extends from housing 102to also support first leg 330.

Alternatively, termination end 320 may extend from bottom 150 of housing102. In this embodiment, termination end 320 proceeds in a verticaldirection along support 334 and then bends at bend section 332 toreverse curve section 340.

Curve section 340 includes a convex portion 344. Convex portion 344includes a first slope 360 and a second slope 362. First slope 360 maybe defined by angle a″, which is formed from the horizontal direction.The horizontal direction is defined at bottom floor 170 of opening 104.Angle a″, which is oriented from the rear of outlet 100, may range up toand including an angle of 45°, with a preferable angle of 45°. Inaddition, a height 372 of convex portion 344 from bottom floor 170 mayrange from about 0.80 inches to about 1.07 inches, with a preferableheight of approximately 0.83 inches.

It should be noted that a height 380 of support 334 maybe adjusted toaccommodate the various angles. In addition, height 380 may remainconstant and the change in the angles may be made by changing the bendof curve section 340. At the preferred angle of 45° for angle a″, height380 does not extend above bottom floor 170. In addition, height 380 isless than both height 180 and 280.

Within outlet 100, contacts 3, 5, and 7 are the same structure and thus,the description described as to contact 3 also applies to contacts 5 and7.

Contacts 1-9 having reverse curve or curve sections 140, 240, and 340allow outlet 100 to mate with both in-specification andout-of-specification plugs without damaging contacts 1-9.

FIG. 7 depicts a cross sectional view of an in-specification, 8 positionplug 500 being mated with outlet 100 at contact 1. It should be notedthat plug 500 has plug contacts 1-8 that align with all contacts 1-8 inoutlet 100, but that FIG. 7 only shows plug contact 1 with contact 1 ofoutlet 100. Plug 500 has a thickness 510 measured from a plug top 502 toa plug bottom 504 of 0.232 inches. Plug bottom 504 is also the contactsurface for contact 1.

FIG. 8 is a similar cross sectional view depicting plug 500 having athickness 510 of 0.242 inches between plug top 502 and plug bottom 504.The variation in the thickness between plug top 502 and plug bottom 504may be due to crimp variations in terminating plug 500. When plug 500 isassembled, either in the field or by a manufacturer, the plug contactsare crimpled in the plug housing to make electrical contact with wiresin the plug. Different crimping tools and/or pressure will result in avariance in the distance between the plug top 502 and plug bottom 504.

FIG. 9 is a cross sectional view depicting an out-of-specification plug600. Plug 600 includes a plug top 602 and a plug bottom 604. Plug bottom604 is also the contact surface for contact 1. A thickness 610 betweenplug top 602 and plug bottom 604 is 0.254 inches, which is over theupper specification limit of 0.242 inches. This may be created by plug600 being under-crimped. Plug 600 enters outlet 100 and plug bottom 604rides over convex portion 144 and enters concave portion 142. Once plug600 crosses the peak of convex portion 144, deflection of contact 1 isminimized because contact 1 curves away from plug bottom 604. Reversecurve section 140 prevents deformation even when out-of-specificationplugs are used.

FIG. 10 is a cross sectional view of outlet 100 depicting a 6 positionplug 700 at contact 1 of outlet 100. Plug 700 lacks plug contacts inpositions 1 and 8 and a plug housing 706 comes into contact with contact1. A thickness 710 of plug housing 706 aligned with contact 1 may exceedthe thickness for plug contacts and thus, the 6 position plug can deformconventional outlet contacts.

As shown in FIG. 10, as the plug 700 enters outlet 100, plug housing 706rides over convex portion 142 144 and enters concave portion 144 142.Once plug 700 crosses the peak of convex portion 142 144, deflection ofcontact 1 is minimized because contact 1 curves away from plug housing706. Reverse curve section 140 prevents deformation when 6 positionplugs are used.

As stated above, within outlet 100, contacts 1 and 8 are the samestructure and thus, the description described as to contact 1 alsoapplies to contact 8 with respect to plugs 500, 600, and 700.

FIG. 11 depicts a cross sectional view of plug 500 being mated withoutlet 100 at contact 3. As explained above, plug 500 has a thickness510 measured from plug top 502 to plug bottom 504 of 0.232 inches. Plugbottom 504 physically contacts contact 3 as desired. FIG. 12 illustratesplug 500 with a thickness 510 of 0.242 inches between plug top 502 andplug bottom 504. Plug bottom 504 physically contacts contact 3.

FIG. 13 is a cross sectional view of plug 600. As explained above, plug600 has a thickness 610 of 0.254 inches between plug top 602 and plugbottom 604, which is over the upper specification limit of 0.242 inches.This may be created by the plug contact being under-crimped.

As shown in FIG. 13, as the plug 600 enters outlet 100, plug bottom 604travels along the length of contact 3. As plug bottom 604 passes overconvex portion 344, plug bottom 604 deflects second slope 362 downtowards a base 620. Due to the angle between the first slope 360, secondslope 362, and bend section 332, second slope 362 becomes horizontal andplug bottom 604 rides along second slope 362, which is now in thehorizontal position. As plug 600 is inserted and second slope 362deflects to the horizontal position, second slope 362 continues toremain horizontal and no further deflection of contact 3 occurs. Thisprevents contact 3 from being deformed by out-of-specification plugs.

As stated above, within outlet 100, contacts 3, 5, and 7 are the samestructure and thus, the description described as to contact 3 alsoapplies to contact 5 and 7 with respect to plugs 500 and 600.

With respect to contacts 2, 4, and 6, convex portion 244 also deflectswhen plugs 500 and 600 are inserted into outlet 100. Convex portion 244deflects so that contacts 2, 4, and 6 are not damaged when plugs 500 and600 are inserted into outlet 100.

The invention being thus described, it will be obvious that the same maybe varied in many ways. Such variations are not to be regarded asdeparture from the spirit and scope of the invention, and all suchmodifications as would be obvious to one skilled in the art are intendedto be included within the scope of the invention.

1. A telecommunications outlet comprising: a housing that is shaped toreceive a plug, said housing having a support disposed within saidhousing; and a first contact having a first end that is disposed under alip of said housing, a termination end that exits a rear of saidhousing, and a bend section, said bend section is supported by saidsupport, wherein said first contact includes a first reverse curvesection disposed between said first end and said bend section, saidfirst reverse curve section includes a convex portion and a concaveportion, said concave convex portion is configured and dimensioned tohave contact with said plug so as to prevent deformation of saidcontact.
 2. The telecommunications outlet of claim 1, wherein saidconvex portion is disposed adjacent to said concave portion.
 3. Thetelecommunications outlet of claim 2, wherein said convex portionincludes a first slope and a second slope and said concave portionincludes said second slope and a third slope, said concave sectiondisposed adjacent to said bend section, said third slope is configuredto deflect to a maximum amount.
 4. The telecommunications outlet ofclaim 1, further comprising a second contact that is supported by saidhousing, said second contact has a second reverse curve section, whereinsaid first reverse curve section has a different structure from saidsecond reverse curve section.
 5. The telecommunications outlet of claim4, wherein said first contact and said second contact form a tip andring pair.
 6. The telecommunications outlet of claim 4, furthercomprising a third contact that is supported by the said housing, saidthird contact has a curve section.
 7. The telecommunications outlet ofclaim 6, further comprising a fourth contact that is supported by thesaid housing, said fourth contact is shaped similar to said secondcontact.
 8. The telecommunications outlet of claim 7, further comprisinga fifth contact that is supported by said housing, said fifth contact isshaped similar to said third contact.
 9. The telecommunications outletof claim 8, further comprising a sixth contact that is supported by saidhousing, said sixth contact is shaped similar to said second contact.10. The telecommunications outlet of claim 9, further comprising aseventh contact that is supported by said housing, said seventh contactis shaped similar to said third contact.
 11. The telecommunicationsoutlet of claim 10, further comprising an eighth contact that issupported by said housing, said eighth contact is shaped similar to saidfirst contact.
 12. The telecommunications outlet of claim 1, whereinsaid plug is an in-specification plug.
 13. The telecommunications outletof claim 1, wherein said plug is an out-of-specification plug.
 14. Thetelecommunications outlet of claim 1, wherein said outlet is a RJ-45outlet having at least 8 contacts.
 15. The telecommunications outlet ofclaim 1, wherein said first reverse curve section includes a first slopedefined by a first angle formed from a horizontal direction, a secondslope defined by a second angle formed from said horizontal direction, athird slope defined by a third angle formed from said horizontaldirection.
 16. The telecommunications outlet of claim 15, wherein saidfirst slope and said second slope form said convex portion, and saidsecond slope and said third slope form said concave portion, said secondslope is approximately 12 degrees to approximately 20 degrees orientedfrom said horizontal direction and from a front of said housing thatreceives said plug.
 17. The telecommunications outlet of claim 15,further comprising a second reverse curve section, said second reversecurve section includes a fourth slope defined by a fourth angle formedfrom said horizontal direction, a fifth slope defined by a fifth angleformed from said horizontal direction, and a sixth slope defined by asixth angle formed from said horizontal direction.
 18. Thetelecommunications outlet of claim 17, further comprising a curvesection, said curve section includes a seventh slope defined by aseventh angle formed from said horizontal direction, and an eighth slopedefined by an eighth angle formed from said horizontal direction.